Forms for the casting of concrete



Nov. 13, 1962 R. KATZ 3,063,122

FORMS FOR THE CASTING OF CONCRETE Filed March 22, 1961 6 Sheets-Sheet l R. KATZ Nov. 13, 1962 ASTING OF arch 22, 1961 6 Sheets-Sheet 2 Nov. 13, 1962' R. KATZ 3,063,122

FORMS FOR THE CASTING OF CONCRETE Filed March 22, 1961 6 Sheets-Sheet 5 Nov. 13, 1962 R. KATZ FORMS FOR THE CASTING OF CONCRETE Filed March 22, 1961 6 Sheets-Sheet 4 Nov. 13, 1962 R. KATZ FORMS FOR THE CASTING OF CONCRETE 6 SheetsSheet 5 Filed March 22, 1961 R. KATZ I FORMS FOR THE CASTING 0F CONCRETE 6 Sheets-Sheet 6 Nov. 13, 1962 Filed March 22, 1961 "ited tates I atnt EfifiEJZZ Patented Nov. 13, 1962 ll flee 3,063,122 FORMS FOR THE CASTING F CONCRETE Robert Katz, Tivoli, Primrose Ave, Bishopscourt Estate, Claremont, Cape Province, Republic of outh Africa Filed Mar. 22, 1961, Ser. No. 97,532 Claims priority, application Republic of South Africa July 17, 1958 4 Claims. (Cl. 25--131.5)

This invention relates to shuttering for use in the casting of concrete structural members or for casting concrete around previously erected steel structural members.

Broadly two types of shuttering are in conventional use, namely timber shuttering, on the one hand and sheet metal shuttering, usually steel, on the other hand. Both types of shuttering have their drawbacks, timber being expensive and having a not very long life and furthermore, requiring much time and much skilled labour for erection in position for casting. Furthermore, timher which may be used on one job, may sometimes not be suitable for another job, because of variations in the dimensions of the concrete structural members to be cast. Conventional steel shuttering on the other hand, comprises a large number of parts for adjustability in dimensions, requiring much time and skilled labour, for assembling and supporting it in position for casting, particularly if it is to be supported in an elevated position.

It is an object of this invention, to provide steel shuttering which is durable and which is suitable for the casting of concrete beams and columns, or for encasing in conrete previously erected steel beams and columns. It is a further object of this invention, to provide shuttering which may be easily assembled into shuttering units to predetermined dimensions at a central work place, if desired, say at ground level, or elsewhere, from where they may be transported and lifted or hoisted into casting position and supported there.

According to the invention, concrete forms, for defining in assembled combination upwardly open cavities within which concrete may be cast, comprises a plurality of thin metal sheet members arranged in assembly to overlap one another and to slide telescopically one relative to and over another, each member having an outwardly projecting flange and a plurality of longitudinally slotted holes spaced longitudinally in series in the flange, the slotted holes of overlapping flanges being adapted to come into register the flange being a stiffening and connecting means; at least one U-clamp member for embracing such an assembly on three sides to provide support against outward bulging of the sheet metal members under internal pressure directed outwardly and comprising a transverse bar and a pair of laterally spaced upright posts having upper and lower ends the posts being fast with the transverse bar at their lower ends; and fastening means for engaging with the slotted holes in the flanges of the members for securing the flanges to the upper ends of the posts of the U-clamp member; whereby said parts can conveniently be pro-assembled anywhere into conveniently transportable section units of predetermined cross-sectional and longitudinal dimensions, and whereby the pre-assembled shuttering sections can thereafter be lifted, joined longitudinally in the pre determined length, and fixed in place for casting.

A plurality of U-clamp members may be provided spaced longitudinally in series, and at least one of the U- clamps may be provided for joining and supporting longitudinally overlapping sheet metal members, the fastening means engaging with slotted holes in register in the flanges of overlapping members, and at least one other U- clamp member may be provided for embracing the assembly at a non-overlapping region.

The sheet metal members may be of U-section, having the outwardly projecting flanges at the upper edges of the U-section, of substantially Z-section, and of substantially J-section. The flanges preferably have downwardly projecting return lips, and sheet metal members adapted to overlap longitudinally, then have flanges in which the flange and return lip of the one member, nests snugly within the flange and return lip of the mating member. Where one or both cross sectional dimensions of structural members to be cast are supstantially constant, then the sheet metal members may be of U-section. Variations in depth of structural members, can then be provided for by using pairs of longitudinally overlapping and mating J-section members with one or more pairs of longitudinally overlapping and mating U-section members. Where structural members to be cast have dilferent Widths, then Z-section shutter members may be used. If the structural members vary also in depth, then J-section members may be used with the Z-section members. If columns have to be cast, then an ordinary beam form may be closed off by attaching a panel over the open end of the beam shutter or if desired, a pair of beam shutters may be mated with opposed cavities.

Further features of the invention will become apparent from the following description with reference to the accompanying drawings.

in the drawings FIGURE 1 shows a three dimensional view of an assembled unit of U-section members ready for hoisting into position;

FIGURE 2 shows a front elevation of one type of U-clamp member;

FIGURE 3 shows a three dimensional view of 2- and J-type metal sheet members;

FIGURE 4 shows diagrammatically the combination of U- and J-section members to define a deep cavity of a particular width;

FIGURE 5 shows diagrammatically the combination of Z- and J-section members to define a deep cavity of variable width;

FIGURE 6 shows a three dimensional detail of Z- and J-section members and part of a U-clamp member in position;

FIGURE 7 shows a three dimensional view of the type of U-clamp member of FEGURE 6;

FIGURE 8 shows a three dimensional view of an assembly of Z- and J-section members and the U-clamp member of FIGURE 7;

FIGURE 9 shows a front elevation of an assembly of another type of U-clamp member with four sets of 2- section sheet metal members;

FEGURE 10 is a part sectional elevational detail at FIGURE 11 is a part sectional elevational detail at XI-XI;

FiGURE 12 shows a detail front elevation of the upper end of a tubular sleeve part of the U-clamp member of FIGURE 9 and of the co-acting telescopic member;

FIGURE 13 shows a detail front elevation of the upper end of a telescopic member of the U-clamp member of FiGURE 9;

FIGURE 14 shows a detail sectional front elevation of the end of the tranverse bar of the U-clamp member of FIGURE 9;

FIGURE 15 shows a front elevation of an assembly of members for casting a column;

FIGURE 16 shows a front elevation of an assembly of members for casting a very deep column;

FIGURE 17 shows a detail front elevation of the telescopic members of FIGURE 16 in abutment;

FEGURE 18 shows diagrammatically a front elevation of an assembly for casting a deep column;

FIGURE 19 shows a detail in three dimensional form of a tubular post U-clamp member and sheet metal members; and

FIGURES to show diagrammatically front elevations of various arrangements of sheet metal members and the U-clamp member of FIGURE 7 for the casting of columns.

Referring to FIGURE 1 there is shown a unit section of assembled members generally designated by reference numeral 10 and defining a cavity 12 within which a cement or other such mix may be cast. The section unit 10 as shown comprises a pair of U-section sheet members 14, 14a, having floor portions 16, 16a, side walls 18, 18a, flanges 20, 20a having longitudinally spaced slots 22, 22a and downwardly turned lips 24, 24a, and longitudinally spaced U-clamp member 26 secured to flanges 20, 20a. Floor portion 16a and side walls 18a of U-section member 14a nest slidably in U-section member 14, the flanges 20 and lips 24 of member 14 nesting within flanges 20a and lips 24a in sliding relationship. The slots 22 and 22a in nesting flanges are adapted to come into register. The pair of members overlap longitudinally at 23.

Referring to FIGURE 2, U-clamp member 26 comprises a transverse bar 28 having a centrally disposed pin 30 and laterally spaced posts 32 and 34. The post 32 is made fast with transverse bar 28 and has an outwardly extending downwardly sloping brace 36, having a bracket handle 38. The post 34 has a similar brace 36 and handle 38 and has also a foot 40 and holes adapted to come into register with holes 42 spaced laterally in series in transverse bar 28 for bolting at variable lateral distances from the post 32. Each post has a transverse shoe 44 having a hole through which a bolt is adapted to pass and through slots 22 and 22a in register to bolt the transverse shoes 44 and flanges 20 and 20a together.

Referring to FIGURE 3, there are shown sets of Z- section members 46 and 48 and sets of J-section members 50 and 52. Set 46 comprises members 54 and 54a having floor portions 56 and 56a, side walls 57 and 57a, flanges 20, 20a, slotted holes 22 and 22a and downwardly turned lips 24 and 24a. Floor portion 56a and side wall 57a of member 54a are adapted to nest slidably in floor portion 56 and side wall 57, and flange 20 and lip 24 of member 54 are adapted to nest slidably in flange 20a and lip 24a of member 54a. Members 54 and 54a of set 46 overlap longitudinally at 58. Similarly set 48 comprises members 60 and 60a having floor portions 62 and 62a and side walls 64 and 64a, and flanges 66, 66a with slots 22, 22a and turned down lips 68, 68a overlapping longitudinally at 58. The floor portions 62 and 62a, side walls 64, 64a, flanges 66, 66a, and lips 68, 68a nest slidably in similar fashion. Set 50 comprises J-section members 72, 72a having side walls 74, 74a, flanges 76, 76a, with slots 22, 22a, and turned down lips 78, 78a. Set 52 similarly comprises J-section members 80, 80a having side walls 82, 82a, flanges 84, 84a, with slots 22, 22a and turned down lips 86, 86a. The various sets 46, 48, 50, and 52 are shown as overlapping at 58 and 70.

Referring to FIGURE 4, there is shown diagrammatically a cross-section of the mating between a U-section member 14 and J-section members 72 and 80, the side walls 72 and 80 of J-sections overlapping the side walls 18 of the U-section. In FIGURE 5 there is shown a cross-section of Z-section members 54 and 60 and mat ing J-section members 72 and 80.

In FIGURE 6 is shown, in detail, Z-section and J-section members overlapping along regions 88. Referring also to FIGURES 7 and 8, the U-clamp member shown comprises transverse bar 28, pin 30, and posts 90 laterally adjustable by means of holes 91 in transverse bar 28 at variable spacings between them. Each post 90 comprises a sleeved part 92 and a telescopic member 94 having spaced holes 96 for attachment at varying heights by means of set screws to the sleeve part 92. Each telescopic member 94 has a transverse shoe 44 having a hole and is adapted to abut the underside of the flanges 20 of the sheet metal members 14, 54, 60, 72, 80. A transverse shoe 44 is adapted to fit behind lips 24, 24a, 68, 68a, 86, 86a of the flanges of the sheet metal members. The sleeved parts have sidewardly slopping braces 36 made fast at their upper ends with the sleeved parts, both braces and parts have holes at their lower ends adapted to come into register with holes at the ends of the transverse bar for being made fast thereto. The telescopic members 94 are provided with auxiliary posts 97 and braces 98 for lateral support. The auxiliary posts 97 are adjustable in position relative to transverse bar 28 by means of feet 99 and laterally spaced holes 100 in transverse bar 28, the braces 98 being adjustable in height by means of holes 102 in auxiliary posts 97 and holes 96 in telescopic members 94.

Referring to FIGURES 9 to 18 there is shown a U- clamp member of alternative construction and comprising transverse bar 28 of angle section, pin 30, tubular posts 90, braces 36, and telescopic tubular elements 94. A post 90 comprises sleeve part 92, pin 104 at its lower end and receivable in any one of holes 91 for variable lateral spacings between posts. Each pin 104 has a transverse hole 106 adapted to receive taper locking pin 108. The brace 36 of a post is made fast at its upper end with sleeve part 92 and has a downwardly projecting pin 110 at its lower end and receivable into any one of a plurality of laterally spaced holes 112 (see FIGURE 14) having their axes at right angles to those of holes 91 and being spaced correspondingly. The pin 110 has a transverse hole adapted to receive taper locking pin 114.

The sleeve part 92 has one or more holes 116 with which holes 96 come into register. A locking pin 118 is receivable into holes in register. The spacing between holes 116 being slightly different from that between holes 96 a wider range of adjustments in height is provided. At the upper end of each telescopic member there is provided a transverse shoe 44.

Stiff sheet metal panels 120 (FIG. 22) having upstanding lips 122 at their edges and laterally spaced rows of slots extending longitudinally are provided for bridging the space between flanges in order to provide a form unit for casting a column. The slots in the panel 120 are adapted to come into register with the slots 22 and 22a in the flanges of the sheet metal members for bolting the members together.

In FIGURES 20 to 25, there are shown various arrangements of U, 2, and J-section members together with a stiff panel and with U-clamp members to define a cavity 12 for the casting of a concrete column. Greater depth of column can be obtained by using tubular distance pieces 124 adapted to receive bolts passing through them.

In use, sheet metal members are mated in the dimensions of the required form and are then divided and secured in convenient section lengths to the U-clamp members. Assembly into section lengths may take place by semi-skilled labour at a work place under the supervision of a supervisor. When assembled, the various section lengths may be hoisted (if necessary) into an approximate position, longitudinally overlapping to comprise the complete form and supported by support posts (not shown) engaging with pins 30. The hoisting may take place via hoist rope 126.

A great advantage of this invention is that sections lengths may be assembled at a convenient work place and may then be delivered for positioning. The preliminary rough positioning may be done by relatively unskilled labour, and thereafter the shuttering units may be finally lined up and located in the casting position by skilled labour. In conventional practice, adjustable forms for beams or columns must be assembled in final position for casting, and cannot be pre-assembled. Shuttering for a beam or a column is usually used at an elevated position thus making difficult, dangerous, and time-consuming its assembly at such a position. Use of shuttering as described in the specification and as shown in the drawings has proved in practice to lead to substantial savings in time and in labour in the erection of multistorey buildings.

Referring to FIGURES 9, 15, 18 and 16, there are shown assemblies for columns having cross-sectional dimensions varying from small to large, that shows the versatility of the invention.

This application is a continuation-in-part of my application Serial No. 825,471, filed July 7, 1959, for Shuttering for the Casting of Concrete now abandoned.

I claim:

1. An improved metal form defining an upwardly opening rectangular cavity within which concrete may be cast, said form being preassembled in a variety of possible dimensions in the most convenient 'work area and in section units convenient for transporting and hoisting into casting position, each section unit comprising in combination: two elongated Z-shaped sheet metal members each comprising a flat side portion, an inwardly projecting flat bottom portion in angular relation to said side portion and an outwardly projecting upper flange portion in angular relation to said side portion and said upper flange portion having a multiplicity of longitudinally spaced openings therein, said Z-shaped members being assembled with said bottom portions overlapping one another to provide a U-shaped trough and said flange portions projecting outwardly from said trough; two elongated J-shaped sheet metal members, each comprising a flat side portion and an outwardly projecting flange portion having a multiplicity of longitudinally spaced openings therein, said J-shaped members overlapping and lying inside the side portions of said Z-shaped members and with the flanges of said J-shaped members projecting outwardly and disposed parallel to and spaced from said flange portions of said Z-shaped members, and a plurality of longitudinally spaced supports, each comprising a bar extending transversely across the bottom portions of said Z-shaped members and having end portions projecting laterally beyond the side portions of said members, a pair of laterally spaced posts extending up along the outside of said Z-shaped members, passing through se lected openings in the flanges of said Z-shaped members and extending to the flanges of said J-shaped members, means securing the lower ends of said posts in selected spaced positions on said transverse bar, means securing said flanges of said J-shaped members to the upper ends of said posts and angle brace members extending between and secured to the laterally projecting end portions of said transverse bar and said posts at a distance from I said bar, each of said posts comprising a plurality of elongated elements which are longitudinally slidable relative to one another to vary the length of said posts and means securing said elements to one another in selected position, said Z-shaped members, J-shaped members and supports when assembled, constituting a substantially rigid self-supporting structure adapted to receive concrete cast in said form.

2. An improved metal for-m according to claim 1 in which each of said posts comprises an upper element, a lower element of a cross-sectional shape telescopically to receive said upper element and a shoe carried at the upper end of said upper element and engaging the flange of the respective J-shaped member, said shoe having a hole which is aligned with a selected hole in the flange of said J-shaped member to receive said means securing said flange to the post.

3. An improved metal form according to claim 2 in which said lower post elements terminate below the flanges of said Z-shaped members and said angle brace members are secured to the said lower elements of said posts.

4. An improved metal form according to claim 1, comprising a plurality of sections each comprising said two z shaped members and two J-shaped members, the members of one section overlapping the corresponding members of an adjacent section with corresponding flange portions of said members overlapping one another and a selected hole in one flange portion, overlapping a selected hole in the overlapping flange portion, one of said supports being located in the region of said overlapping with said securing means for attaching the post upper ends to the J-shaped members passing through said overlying holes and uniting the overlapping flange portions of said J-shaped members with said posts.

References Cited in the file of this patent UNITED STATES PATENTS 

